Method of forming radiators



6 Sheets-Sheet l J. KARMAZIN METHODOF FORMING RADIATORS Filed July 5. 1924 Dec. 17, 1929.

Dec. 17, 1929. J, KARMAZIN 1,740,098

METHOD OF FORMING RADIATORS Filed July 3, 1924 6 Sheets-Sheet 2 TTOF/VEY Dec. 17, 1929. J, KARMAZlN 1,740,098

METHOD 0F FORMING RADIATORS Filed July 5, 1924 6 sheets-sheet 3 5MM WM fr0/Puffy Dec. 17, 1929. J. KARMAZIN 1,740,098

METHOD OF FORMING RADIATORS Dec. 17, 1929. J KRMAZIN l 1,740,098

METHOD OF FORMING RADIATORS Filed July 3, 1924 6 Sheets-Sheet 5 5 y @ew fra/fwn Dec. i929.

J. KARMAZIN METHOD OF FORMING RADIATORS Filed July 5. 1924 6 Sheets-Sheet Patented Dee. 17, 1929 UNITED STATES JOHN KABMAZIN, F DETROIT, MICHIGAN METHOD or -FonmNG numerous Application med my s,

This invention relates to radiators suitable for use with internal combustion engines using cooling water, and partlcularly to 'radiators of the ltypedisclosed 1n my pendmg g application Ser. No. 641,850. i

Radiators for water cooled internal combustionengines require the'passage of water in one direction through one setr of passages,

and the passage of air in a different directionv w throu h other passages. For high eiiciency it is esirable to have low reslstance to an' low and also to the flow of water, andyet to divide u the circulating water and a1r 1nto suiicient y small streams so that the water is may be cooled rapidly, the heat thus generated being conducted to the vair through th1n metallic walls. It is of great importance that each part of the radiator be active 1n d1str1buting this heat.

There are two principal ty es of radiators;

one the honey-comb type o radiator, made up of corrugated strips suitably spaced apart to form a conduit for the water, the other being the tube type made up of a number of e spaced fiat sheets of metal through whlch are Passw. a number of tubes to conduct the cooling water. The assembly of radiators of this type which have been made hitherto has been found to be a very expensive process.

The radiator disclosed in my application above identified resembles generally the lin and tube type f radiator but it is constructed along lines dijering widely from radiators as they have been made prior to my invention. Said radiator comprises a stack of superposed elements,f each comprising tapering tubular projections, separated by a laterally extending iin which is integral with the tubes, the projections of one element being adapted to telescope into the projections of the adjacent element, whereby continuous water tubes are formed. v

Une objectof the present invention is to provide a machine and method for formin and assembling the elements of my improve radiator as described above.

A further object of the present invention is to provide\a method for constructing a radiator from a strip of sheetmetal.

A further object of the invention is to prov1924. Serial No. 723,860.

vide a method of radiator construction comprising the mechanical forming and assembling of radiator elements.

A further object of the invention is to provide a method of manufacturing radiators according to which a strip of sheet metal is subjected to working such that it is brought to a condition wherein parts of the sheet have become transverse tubes adapted to conduct water, and' to assemble sections of the strip so 50 formed into a radiator by telescoping said tubes together to form continuous water conduits through the assembled strip sections.

A further object of the invention is to provide a method of manufacturing radiators according to which a strip of sheet metal is progressively deformed to provide transverse tubes without materially thinning or weakening the sheet and to assemble the sheet so formed into a radiator. 7,0

A further object of the invention is to provide a method of manufacturing radiators according to which interchangeable parts are made and assembled in such a way as to provide a plurality of transverse tubes.

Vith these and other objects in view, m invention consists in novel processes', whic will be hereinafter described and which are illustrated in the drawings,l said drawings illustrating one type of machine by which my 30 improved process may be practiced.

In the drawings:

Figure 1 is a longitudinal elevation of a machine embodying my invention.

Figure 2 is a detail of the element cutting 85 devices.

Figure 3 is a detail of the automatic clutch controlling device.

Figure 4 is a plan View of the machine shown in Figure 1 certain part being broken 90k away for greater clearness.

Figure 5 is a'n elevation of the element forming and feeding devices.

Figure 6 isa plan view of the forming die.

Figure 7 is a section on the line 7-7 of 95 Fi re 6.

igure 8 is a plan view of the element strip in the process of forming the same.

Fisgure 9 is a section on the line 9-9 of Figure projections extending therefrom.

Figure 10 is a vertical section thru the uper andlower dies, on the line 10-10 of igure 7. Figure 11 is a front elevation of an assembled radiator. Figure 12 is an enlarged detail view of a portion of the radiator. i

My invention contemplates the formation from a strip of material preferably metal such as brass or copper, of a strip of radiator element forming material, comprising aA fiat fin portion having integral tubular Such a strip in the process of formation is illustrated in Figures 8 and 9, the strip being indicated generally by the numeral 15. The machine which I have illustrated inthe drawings as bestadapted for carrying out my processcomprises a strip deforming tube forming and punching machine, a device for supporting aroll of strip material to be fed to the machine, a feeding device7 means for cutting the formed strip into elements of a predetermined length, means for receiving and stacking the elements so formed, and means for compacting the stack of element into a radiator. The strip deforming and punching machine, by which a strip of 'fiat material is formed into a strip of radiator element forming material will be first described.

The machine frame comprises a supporting base 16 (Figure 1) carried on pedestals 17, to which base are secured uprights 18, formed with bearings 19 adapted to receive the crank shaft 20. Power is applied to the crank shaft thru the belt wheel 21. Rotation of the crank shaft reciprocates a plunger 22 which is guided for vertical movement in 'the uprights 18. y

The die mechanism which operates on the ystrip of sheet material v15 comprises downwardly extending forming punches and cutters carried by 'the upper male die member 23 on the plunger 22, and cooperating recessed female dies carried on lthe lower die member 30 on the base plate16. This die mechanism is shown in detail in Figures 6 and 7in which the strip material advances from right to left. The plunger 22 carries the upper die member or head 23 guided for vertical movement by rods 231. Secured to head 23 is a plate 24 which is drilled to receive and support 'the forming, punching and cutting tools 25, 26, 27, 28 and 29. Secured to the supporting' base 16 is a recessed plate 30 provided with recessed dies 261, 271, 281, and 291, in alignment respectively with the forming and other tools 26, 27, 28 and 29. Below 'the dies 261 are spring pressed plungers 31 adapted to lift the strip being formed out of the die recesses, to permit the strip to be fed forward. n intermediate die member 241 perforated to permit the passage of plungers 25, 26, 27, 28 and 29 therethrough 1s supported on the plate 30 by the spacing blocks 241 and is secured thereto by the pins The tool 25 is simply a fiat faced plunger, adapted to flatten or smooth out the metal strip 15 which is drawn out of shape as it approaches the rst lforming die 26. The function of dies 26 and 261 is to progressively form on and from the strip 15 rows of tubular projectionsv transverse to the strip, and to accomplish this result without materially thinning and weakening the strip. To this end the first dies 26 which the strip encounters are adapted to form broad shallow depressions such as 33 in the strip, this operation reducing or drawing i'n the width of the strip as clearly shown in Figure 8.V The succeeding dies 26 progressively deepen and narrow the depressions 33, as shown in Figures 8 and 9 but do not further reduce the width of the strip, or materially reduce the thickness at any point. In other words, the first operation displaces sufficient metal into the die 26 for the formation of the tubes, andthe suc-` ceeding operations progressively re-form this metal into tubes of the proper si'ze shape and thickness. By thus starting with an initially 'thin 'strip of metal15 and forming the tubes 34 therefrom without materially thinning the strip it is possible to form watertight tubes of sound metal and stillkeep the weight of 'the assembled radiator very low because of the initially thin strips of which it is composed.

The tools 27 and 271 are punches, for removing or punching out the bottom of the fully formed tube. The tools 28-281 are punches adapted to perforate the strip between the tubes 25, for the purpose of securing improved circulation of air about the tubes, and the tools29 and 291 are cutters adapted to 4trim the edges of the strip and also to regulate the feed of the strip between reciprocations 0f the plunger head 23. The cutters are as long as the distance between centres of adjacent dies 26 and the forward edges thereof, as defined by the spacing members 241, form stops 242 which halt the forward movement of the strip after eachdepression of the upper die member so that a stripas long as the distancebetween the die members is cut off at each operation of the cutters and the vstrip is advanced the correct distance for the next forming step.

Since commercial roller strip metal such as my machine is adapted to use, is rarely or never of uniform thickness, one edge of thev strip being almost invariably, slightly thicker 'than `the other edge, l design the row of forming dies adjacent one edge of the strip to operate on metal of a slightly different thickness than the row adjacent the opposite edge to provide for uniform operation of the die and uniform operation upon both sides of the strip.

The means for supporting the supply roll 'of strip metal are constructed as follows. A bracket 37 is pivotally secured, to a projection 36 on the supporting base 16 and to the bracket 37 is pivoted an arm 38 carrying a supporting Spindle 39 adapted to receive a roll of strip metal 40. The strip leaving said roll passes thru an oil bath 41' into which it is depressed by a roller 42, under a guide rod 43 and thence to the forming machine. `As hereinbeforc stated the dies of one edge of the forming machine are adapted for metal of greater thickness than the dies at the opposite edge i. c. by making one row plungers 26 adjacent one side of the die .001,inch longer or shorter than the; plungers of the other rows. The supply roll must therefore be turned so that the lthicker metal will be opposite the proper dies..y It will be seen that this condition may be satisfied on the roller strips by turning the Aroll so that'the strip will leave some rolls at the top and other rolls at the bottom, according to which is the thickest side of the strip when rolled or coiled on the spool. It is desirable, however that the strip shall leave the roll at approximately the same position' relative to the forming -machine and the oil bath. To secure this 'result the arm 38 which carries the strip roll'is pivoted to the frame 37 and is ada ted to vbe supported at dierent elevations y a stop pin 441 which can be inserted in either of two openings 44 and 45 in the frame 37. In the position of the arm 38 and roll 40 shown in the full linesin Figure l the stop 441 is/inserted in opening 44, and the strip is run off fnom the top of the roll with the thick part opposite the proper row of plungers 26, while in the position of these parts shown in dotted lines the arm is in engagement with the top in opening 45, and the bottom of the roll from which the strip is now fed is at approximately the same place as the top of the roll in the first position.

The means for feeding the strip of'metal 1o the forming machine, and the strip of formed radiatorbuilding material from the forming machine to the cutting and stacking machine is constructed as follows'. A shaft 46, journaled in brackets 47, supported in part by the supporting base 16, is dr1venfrom the crank shaft by, means of pairs of bevel gears 48 and 49A and a connecting shaft 50. A pinion51 on the shaft 46 meshes with a pinion 52 on a short shaft 53. The shaft 46 carries a circumferentially grooved roller 54 and the shaft 53 carries a smooth rollervv55 which engages the roller 54, the line of contact of said rollers being approximately in the plane of the stripr of formed material as it leaves'the forming machine. tween the rollers l54 and 55 is regulated b means of adjustable'springs 56 on rods 5 secured in the 'bracket 47 and extending thru openings in the enlarged journal bearings 531 of the shaft 53. ForI the purpose of lifting Tension bethe upper rollerv to start the strip or for other purposes a hand llever '58 having a toe 59 which contactswith the upper surface of the bracket 47 is pivoted on a rod 60, connected with'the bearings 531 of the shaft 53. fAs clearly shown in Figure l the toe 59 contacts with the bracket 47 at' such apoint that downward pressure on the handle 58 will rock the toe 59 under the lever pivot, and lift the' pivot and with it the shaft 53 and roller' 55.

It will be A understood that while the rota- -tiony of the feed rollers 54, is continuous the feeding movement of the element strip is intermittent. The strip is retained against movement during the forming operation of the head 23 by the stops 242, and at this time there is a slip between/the feed rollers and the strip, each ldepression ofthe head 23 however not only depresses the forming plungers 26, etc` butalso depresses the cutters 29 so that a portion of the edge of the strip equal to the distance between the dies 261 iscut olf and.

when the head 23 and cutter 29 is raised the strip is advanced one lstep b the rollers 54, 55, until the forward edge o the untrimmed portion strikes the stop 242.

The devices forcutting the strip prepared in the forming machine and fed therefrom by the feed rollers 54, 55 comprises cutters suportedin a face plate 61. The upper or ed cutter 62 is held against the face plate Vby screws 63 passing thru slots 64, and is positively secured against upward movement y set screws 65 passing downwardthru a laterally extending part 66 of the face plate y61. The lower or reciprocating cutter 621 isguided for vertical movementby guidey plates 67 secured to the face plate 61. The mechanism for reciprocating the ycutter 621 comprises bell crank 68 which carries, a pin 69 adapted to engage a transverse slot70 in the cutter 621.- Bell crank 68 is pivoted at 71 and is held with the cutter 66 in depressed position by a spring-681 compressed between a part of the bell crank andthe edgeof the face plate 61. The bell crank carries a cam by the cutters is constructedas follows.

In alignment with the strip as it is advanced thru the machine is a frame comprising a base 78 upri hts 79 and a top plate 80.

Between the uprig its 79 extends an elongated element receiving table 81 which is Vsupported on screws 82 extending thru threadedbosses yintegral with the table.7 The! screws 81 are supported in bearings in the top plate 80, and

are provided above said plate with pinions 83 and 84, in mesh. with an intermediate idler 85. Pinion 84 meshes with a `gear 86 having a one way connection with a short shaft carrying a bevel gear 87 which meshes with a bevel gear 88l connected thru a universal joint 89 with the sha-ft 75, which it will be recalledfis driven from the crank shaft By means` ofthe gearing just described the table 81 is lowered as successive elements are placed thereon and the level of thetop of the stack of elements on the table is keptat approximately the level at which elements are delivered by the cutters.

When the desired number of elements havel l 82 may be turned.

latch about its pivot..

Means are'provided for automatically stopping the motion of the machine when a predetermined number oi elements have been made and stacked on the receiving table 81. For this purpose the lowering of the table 81 to a predetermined positiony is utilized to actuate a clutch controlling device. A pin 91 is adjustably secured to the table 81. As the table is lowered in the operation ot the ma.- chine toa position determined'by the adjustment of pin 91, said pin engages a roller 92 carried' by a pivoted latch 93 and rocks the A. notch in the latch receives the end of an arm 94 secured to a shaft 95 controlled by a spring-98. Shaft 95 carries'a finger 96 overlying a clutch pedal 97, which forms one end of a lever, pivoted l at 100, and connected with a link 101 which controls a suitable clutch associated with the driving means for the crank shaft 20.

The operation of the machine is as follows.

A roll of strip material 40 is placed on the supporting spindle 39. The thicker edge of the strip is turned toward the side ofthe machine adapted. to receive it, and the supporting pin 441 is placed in the appropriate opening. If the strip'leaves the roll at thetop, pin 441 is placed in opening 44, while it' the strip leaves the bottom of the roll opening' 45 will be used. The end of the strip is then passed under the roller 42 and the rod 43, over the die block 30, and between the feed rollers 54 and 55, the roller 55 being raised against the tension of springs 56 to permit the entrance of the end of the strip by pressing downward on the handlev 58. The table `81 is then elevated to a position, slightly beanonce punches, the first plunger 26, forms a shal-4 l low depression in the strip. At the same time the cutting tools 29 notch the edges of the strip.y When the plunger head 23 is raised the spring plungers 31 lift the strip outof engagement with the dies 261 etc., permitting the feed rollers 54 and 55, which are continu-y oisly rotated, to advance the strip until the rear edge of the notch cut'by cutting tool 29 engages the stops 242. This movement brings the depressions made by the first series of dies 26 into alignment with the second series ot dies, which dies upon the second downward stroke of the plunger head 23 re-form the depressions to a narrower and deeper'shape, at the same time that the irst dies are forming another series oitV broad and shallow depressions. As the plunger head 23 continues to reciprocate and the strip to be advanced, the

depressions are successively re-formed in succeeding dies until they have assumed the proper shape. The punches 27 then remove the bottom from the depressions and the tubes are complete. The dies 28 and 281 per forate the strip intermediate the tubes, the

cutters 29, already mentioned; trim the edges, and the strip thus formed passes thru the feed rollers 54, 55 and the aperture between the l cutters 62, 621.

As the machine continues to operate, worm v77 on the shaft 46 rotates cam 74 and periodim callybrings cam 73 into engagement with iollower 72, thus rocking the bell crank 68 to lift the knife 621 and cut the formed strip into elements of uniform length. The elements thus formed are superposed on the receiving table,81, said table being slowly lowered thru the rotation of screws 82 by pinions 83, 84 etc., to keep the top of the stack of elements at approximately the level of the cutters, as is more completely described in my copending application Serial No. 641,850 filed May 2,8, 1923.

The cam pin 91 having previously been set to engage the latch roller 92 when the table 81 has been lowered thru a distance correry llG screws 82 land the stack of elements is compacted into the radiator, shown in Figure 11.

This radiator is then removed, the table is restored to initial position and the machine again set in operation. Figure l2 shows on v l ited to the precise construction and method of operation hereinbefore described, but is to be construed as conferring all equivalent machines and processes coming Within the scope of the appended claims.

I claim:

1. The method of forming a' radiator core from flat sheet material, which comprises, forming a plurality of integral single walled cup shaped projections from said sheet, perorating the bottoms of said projections, assembling strips of said sheet material with the perforated projections of one strip registering with the perforated projections of the adjacent strip, and pressing said strips together, with the projections of adjacent strips l in telescoping relation and in permanent engagement.

2. The method of forming a radiator core, which comprises forming a plurality of rows of integral tapered cup shaped projections from a fiat-strip of metal, perforating` the bottoms of said projections, cutting said strip into sections and assembling said sections in superposed relation with the bottom of the projections of one section extending into and pressed into permanent engagement with the top of the projections of the adjacentsection to form i'luid conduits through the core.

3. The method of forming a radiator core from a flat strip of metal, which comprises forming large diameter shallow depressions in said strip progressively re-forming said depressions into smaller dlameter deeper depressions perforating the bottom of said depressions after the forming is completed and assembling sections of said formed strip in superposed relation with the projections of one section extending into the projections of the adjacent section to form water conduits through the core.

4. The method of making a radiator which comprises the steps of forming broad shallow depressions in an undivided strip of sheet material, progressively re-forming said depressions-into recesses of a desired depth and shape, punching the bottom from said recesses to form tubes and superposing sections of the material thus formed.

5. The method of making a radiator which comprises the steps of forming round tubular projections on an undivided strip of sheet material without materially weakening said sheet, superposing sections of the strip thus formed with the tubular projections of one section extending -into the tubular projeccomprises the steps of forming tubular projections on an undivided strip of sheet material without materially changing the thickness of said sheet and superposing elements vof the strip thus formed with the projectlons of adjacent elements in mutually engaging relation.

p7. The method of making a radiator comprising the steps of forming shallow depresl ysions in an undivided strip of sheet material,

4re-forming said depressions into recesses `of a desired size and depth without materially yalteringthe thickness of the material punchlingl the bottoms from said recesses to form 'tubes and superposing sections of the strip thus formed with the tubes of adjacent sections in engaging relation.

8. The method of making a radiator core comprising the step of forming shallow depressions in an undivided strip of sheetvmaterial, thereby reducing the width of said strip, re-forming said depressions into projections f of a desired shape and size without further reducing thewidth of saidstrip, punching the bottoms from said projections to form tubes and superposing sections of the strip thus formed. i

9. The method of radiator construction comprising forming shallow' depressions in an undivided strip of sheet material, thereby reducing the width of said strip, progressively re-forming said depressions into tubular projections trimming the strip to a uniform width and assembling the strip thus 'formed into a heat transfer section.

10. In the manufacture of radiator cores, the method which com rises, producing in a piece of sheet metal ap urality of shallow depressions of predetermined outline, then increasing the depth of the depressions and simultaneously decreasing their outline in a vassembling sections ofthe sheet so ,formed in superposed relation with the tubes of one sec` i tion extending into the tubes of the adjacenty section to form water conduits through the core.

11. yl'n the manu-facture of radiator cores,

the method which comprises, producin in a strip of sheet 'metal a plurality of s allow depressions of predetermined, outline, increasing the depth of these depressions and,

simultaneously decreasing their outline, producing a plurality of\shallow depressions adjacent the deepened depressions, and then further increasing the depth and decreasing the outline of both sets of depressions, the

change in the dimensions of the depressions being so graduated that the metal is not aprpreciabljy thinned in the depressions, perforating the bottom of said depressions and nssernbling sections of the strip so formed in superposed relation with the depressions in alignment,

f 12. In the manufacture of radiator cores, the rnethod which comprises,producing in a strip of sheet metal a plurality oshallow de-v pressions ot predetermined outline, increasing the depth of thesedepressions and simultaneously decreasing their outline, producing a plurality of shallowr depressions adjacent the deepened depressions, then further increasing the depth und decreasing the outline 'of both sets of depressions, punching out the materiel at the bottom of the depressions, the Walls of the depressions being in the 'torni of a plurality of tubes projecting from the sheet, cutting the strip so formed into sections, nssembling said sections in superposed relation with the depression in alignment and pressing the sections together.

13. ln the manufacture of radiator cores, the method which comprises, producing in n strip ot sheet material n shallow centrally srranged initial depression to nnrrow the strip, then producing n similar depression et either side of the tirst depression, and thereafter increasing the depth of the depressions und simultaneously decreasing their outline, pero'rntingI the loot-toms ot' Suid depressions end assembling!" sections oit the'strip so formed in 'superposed relntion with the ends of the dcpressions telescoping together..

ln testimony Whereot l huile nned my signature tothis speeication.

JHN KARMAZlN. 

